I always suggest reloaders invest in a magic marker, and then properly adjust their sizer die....

Can't imagine charging and seating without first making,inspecting, and chambering a dummy round to verify all is well....which it seems, is the way it didn't happen here. To create the bulges on these .243 win cases as a result of the sizer die being out of adjustmentwould likely have produced an out of norm effort with the press and that should have beenthe firstsign that something was wrong. This issue should have been recognized andresolved long before the first live round was even made. A visual of the very first sizing attempt, at the very least,would have showed the problem...

Personally I've never reloaded new or once fired brass without first checking fordiscrepencies in case length, if that is actually the culprit here in tandom with a die set too far down. I ALWAYS trim everything to a consistent length as part of initial case prep. I guess there's folks out there who don'tthink that's important.

Never saw an RCBS FL die that didn't take max length brass, 'course I don't set up with a cam over either.....